Two-shot modified axminster weave



R. R. MATTHEWS 2,718,243

TWO-SHOT MODIFIED AXMINSTER WEAVE 2 Sheets-Sheet 1 Sept. 20, 1955 FiledFeb. 21, 1955 INVENTOR v ATTORNEYS P 20, 1955 R. R. MATTHEWS 2,718,243

TWO-SHOT MODIFIED AXMINSTER WEAVE Filed Feb. 21, 1955 2 Sheets-Sheet 2WITH TWO FRAMES (F16. 7.)

POSITION OF HEDDLES FIG FRONT HEDDLE V REAR HEDDLE 1ST sHoT UP DOWN 2NDsHoT DOWN 7 up WITH THREE FRAMES (FIG. 5.)

POSITION 0F HEDDLES Fla FRONT HEDDLE MIDDLE HEDDLE REAR HEDDLE 1ST SHOTUP UP DOWN 2ND SHOT DOWN oowu UP I INVENTOR BY ,ZE Z 1 ATTORNEYS UnitedStates Patent TWO-SHOT MODIFIED AXMINSTER WEAVE Russell R. Matthews,Cornwall, N. Y., assignor to The Firth Carpet Company, Inc., New York,N. Y., a cor poration of New York Application February 21, 1955, SerialNo. 489,556

Claims. (Cl. 139-401) This invention relates to Axminister carpets andhas for its object the provision of a modified Axminster weave of noveland improved characteristics.

Hitherto,.Axminster weaves produced in needle looms were constructed soas to have three double weft shots to each face row .as it appears inthe finished carpet. While this basic weave has been improved in variousways over the long period .of its use, thisis particularly so withrespect to the old fashioned Imperial Axminster which usuallyhad sixdouble weft shotsto one face row. The Axminster weave as commonlymanufactured today hasthree double weft shots of backing to each facerow. One of thecommon objections to such prior Axminster weaves was itslack of flexibility. In an earlier effort to overcome this basicobjection there was produced a flat or soft Axminster weave which hadappreciably greater flexibility. A patent application on that improvedweave has been filed jointly by Harold E. Wadely and Russell R.Matthews, and is identified as Serial No.

Thepresent invention, however, departs considerably from all thepreviously'known types of Axminster weave by reason of the fact thatonly .acycle of two double weft shots (or a multiple thereof) isrequired for each face row inserted.

As will be more particularly disclosed, this invention provides atwo-shot modified Axminster weave, while :at the same time retaining thefine qualities of Axminster carpeting, namely, unlimitedidesignandcolcr-ranges within the pattern of design. 7

Therefore, it is the principal object of .thisinvention to provide-aflexible, two-shot modified weave Axminster carpeting -,having all theadvantages of .the :previously known practices in the application offace yarn...

Another important purpose of thisinvention is to enable themanufacturersof such a weave toincreasernaterialiy theamount of sizing adhesion tothe 'facetufts and thus prevent them from being pulled out withoutconsiderable difliculty. V

A still further object of .this invention resides in the provision of anAxminster weave by means of which the speed of manufacture can beincreased by one-third, the amount of weft material and/or warp materialcan be decreased by one-third in weight, and the new.modified.

Axminster weave carpet which results lends itself to the economy ofmannfactureand high speed-of production required .by the presentage.

.The nature of this invention will be better-understood from thefollowing detailed description of illustrative embodiments thereof, whentaken inconjunction with Fig. '3 is another warp-wise section of thefabric--em- Patented Sept. 20, 1955 bodying the weave of this inventionhaving a stutter warp added to the construction of Fig. 1;

Fig. 4 is a warp-wise section similar to Fig. 2 in pile looparrangement, but having a stufier warp included;

Fig. 5 shows another warp-wise section of fabric similar to that of Fig.2 but having a stuifer warp used as an additional binding;

Fig. 6 is a table of heddle positions for the weaving cycle utilized inproducing the fabric of Fig. l; and

Fig. 7 is another table of heddle positions applicable in this instanceto the weaving cycle utilized in the fabric of Fig. 5.

Referring to the drawing in more detail, the two-shot modified Axminsterweave shown in .Fig. 1 comprises a plurality of closely spaced doubleweft shots 10 and 12 respectively lying in substantially the same planeand bound together by a forward chain warp 14 and a rearward chain warp16 forming a double warp chain. A length of a pile yarn warp end islooped under each alternate double weft shot 10 and cut to form piletufts 13 of U-shape having an upstanding pair .of legs joined beneaththe corresponding weft shot by a generally horizontal knob formation 19projecting below the adjacent portion of the chain warp 16.

The hpysical arrangement of the double weft filler shots 10 and 12 isdetermined during weaving by tensions on the chain warps 14 and 16.While in the conventional three-shot Axminster weave, at least two warpbeams are necessary, the equal tensionsrequired in'Fig. l (and also Fig.2) of the double chain warp ends makes it possible to weave with onlyone beam, something not heretofore possible in Axminster weaving.

Except for the absence of cut pile the weave shown in' Fig. 2 .issubstantially similar to that described in detail with respect toFig. 1. Alternate double weft filler shots 2i) and 22 disposed insubstantially the same plane are bound together by a forward chain warp24 and a rearward chain warp 26 comprising a double warp chain. Acontinuous pile warp end of yarn 28 is looped under each alternatedouble weft shot 20 and extendsas a loop pile over each double weft shot22 in position intermediate the alternate double weft shots 20. EachU-shaped portion 30 of yarn end underlying the alternate weft shots 20has its connecting part '31 projecting below the chain warp 26 as a flatknob formation. The pile yarn warp ends 28 of this weave lie alternatelyin front of and behind the double weft shots, and are preferably of ayarn that application of steam will cause to form twisted loops 32 overeach double weft shot 22.

In both the constructions of Figs. 1 and '2 the downwardly projectingknob formations 19 and 31 respectively are so exposed in the back as topermit the application of very substantial amounts of adhesive sizingmaterials and thus securely anchor the .pile yarn against removal.

The modified Axminster weaves shownin 'Figs. 1 and 2 have only two warpends in each dent.

The table of Fig. 6 explains the positioning and operation of the heddleframes when only chain warp ends are used in producing the weaveconstruction of Fig. 1. It is also to be noted that the weaveconstruction of Fig. 2 is produced in a similar manner.

The weave illustrated in Fig. 3, which will now berlescribed, representsa distinct modification of the more basic weave of Figs. 1 and 2. Thealso two-shot modified Axminster weave construction of Fig. '3 is shownas comprising a plurality of closely spaced double weft shots 34 and 36arranged with every other double weft shot 36 lying in a substantiallycommon lower plane and .the intermediate double weft shots 34 lying in asubstantially common upper plane. A forward binder warp 38 extends overeach upper plane double weft shot 34 and under each lower plane doubleweft shot 36, and a rearward chain warp 40 extends over each lower planedouble weft shot 36 and under each upper plane double weft shot 34. Filetuft elements 42 formed and cut to U-shape are looped under each upperplane double weft shot 34 and have pairs of free legs. A straight andpreferably fairly thin stuffer warp 44 extends between the binder warp38 and chain warp 40 intermediate the upper and lower plane weft shots34 and 36 immediately beneath the connecting loop portions of the cutpile tufts 42. The presence of the straight stufier warp 44 prevents thebottom parts of the pile tufts 42 from going all the way through theback, and thereby prevents the double weft filler shots 36 and 34respectively from lying within a common plane.

4 of the fabric by reason of the fact that the adhesive backing orsizing material is better able to fill the space be tween two weft shotsthan it is three disposed within the same area.

Standard carpet materials are used in the production of the carpetweaves described herein. The weft materials may be jute, Kraft cordyarns, linen, and the like. For the warp materials, cotton, jute, Kraftcord, glass-centered Kraft cord, rayon, nylon or linen may be used. Thepile It will be seen by reference to the table of Fig. 7 that A threeheddle frames are used in producing the weave illustrated in Fig. 3. Inthe first double weft shot the front and middle heddles will remain upand the rear heddle will be down. During the following double weft shotthe front and middle heddles will be down and the rear heddle will beup.

A still further modification of the novel two-shot modified Axminsterweave construction of this invention is illustrated in Fig. 4 whichresembles the construction of Fig. 2. as well as that of Fig. 3. In thisinstance a plurality of double weft shots 46 and 48 are arranged to lierespectively in a common upper plane and a common lower plane with thelower level weft shots 43 intermediate the upper level weft shots 46 inan alternating relation. A forward binder warp 50 and a rearward chainwarp 52 secure the weft shots 46 and 48 in the position described andhave a straight stuffer warp 54 extending between them in a planeintermediate that of the double weft shots of stuffer material. In thisconstruction a continuous pile yarn warp end 56 is looped under eachupper level double weft shot 46 as a U-shaped portion 58 and extendswithout interruption as a joined loop pile portion 60 above the lowerlevel weft shots 48. While the substantial similarity of the weaveconstructions of Figs. 3 and 4 respectively is apparent, there is oneimportant difference. In the weave construction of Fig. 4 the fullfreedom of pattern color inherent in Axminster weaving is restricted byreason of the use of continuous, uncut pile yarn ends.

yarn warp end material will be Wool, synthetic fibers, mixtures of wooland synthetic fibers or any other known yarns suitable for the purpose.

The modified Axminster carpet weaves with which this invention isconcerned are those in which the pile is formed from yarn drawn fromseparate supplies during the operation of the loom, and such yarns areinserted in the fabric and looped about weft shots. Therefore, the termAxminster as used herein with reference to carpet weaves is to beinterpreted as and limited to pile fabrics produced in the mannerindicated. In those instances where the weave embodies continuouslengths of pile yarn ends, novel effects are obtainable, as illustratedby Figs. 2 and 4, and there is no fixed limit as to pile height, butonly as to pattern by reason of the use of pile yarn ends having areasof different color printed thereon.

The combination of advantages afforded by the modified Axminster carpetweaves as herein described will be more clearly apparent from a shortsummary. The twoshot weaves disclosed are specially adaptable to asizing operation that locks in the tufts more strongly and imparts moreflexibility to the carpet body. The available saving of one-third of theweft material and, in the construction of Fig. 1, one-third of warpmaterials also makes it possible for the manufacturer of these noveltwo-shot weaves to perform a better sizing operation on the fabricwithout the necessity of increasing overall manufacturing costs. Butnone of the other advantages is as important as the time saving inoperation of an Axminster loom.

For example, in a three-shot weave conventional Ax- As shown in thedrawing, the weave of Fig. has much in common with Fig. 2, which hasbeen described in detail. In Fig. 5 a plurality of closely spaced doubleweft shots 62 and 64 are arranged alternately and lie in substantiallythe same plane. In this modification, however, a stuffer warp 66 is usedin conjunction with a rearward chain warp 68. In order to bind togetherthe double weft shots 62 and 64, an additional binder warp 70 is used infront of the rearward chain warp 68 and extends over the intermediatedouble weft shots 62 and under the alternate double weft shots 64. pileyarn warp end 72 is disposed in front of the forward and rearward chainwarps 66 and 68 and also the binder warp 70. This yarn end 72, which maybe a plied one as shown, is looped under each alternate double weft shot64 and extends over each intermediate double weft shot 62 with a twistedopen ring formation 74. In the back of this weave the pile yarn warp end72 runs under the adjacent portion of the binder warp 70 as a dependingknob portion 76 lying substantially below the general level of the back.Ample provision is thus made for sizing adhesion binding of the loopedunder portions of the pile yarn end 72.

The adhesion sizing of the back, which has been omitted from the figuresof the drawing for purposes of clarity, may be of any of thecommercially known rubber, plastic, or newer type washable starchformulations. In this manner it is possible to produce a weave whicheliminates some of the binding functions within the fabric withoutreducing the quality thereof.

The finished fabric is considerably more flexible than a similar onemade with a three-shot Axminster weave, and the pile tufts are boundmuch more tightly into the weave minster loom running at 30 picks perminute, face rows are inserted, while in a two-shot weaving operationrunning at the same speed, face rows are inserted in the same period oftime, thus increasing production It will be understood by those skilledin the art to which this invention pertains that various changes andmodifications may be made in the preferred embodiments that have beenillustrated and described without departing from the principles of theinvention and the scope of the appended claims.

In this weave construction a continuous a x Having thus described myinvention, what I claim as novel and desire to secure by Letters Patentof the United States is:

1. A two-shot modified Axminster carpet weave comprising a plurality ofclosely spaced double weft shots,

pile tuft elements looped under each intermediate double weft shot, achain warp extending over each alternate double weft shot and under eachintermediate double weft 4 shot, a binder warp extending over eachintermediate double weft shot and under each alternate double weft shot,and a stutfer warp extending between the chain warp and the binder warpabove the alternate double weft shots and beneath the intermediatedouble weft shots.

2. A two-shot modified Axminster carpet weave com prising a plurality ofclosely spaced double weft shots under each upper level double weft shotand lying between the binder warp and the chain warp above the straightstutter warp.

3. A two-shot modified Axminster carpet weave comprising a plurality ofclosely spaced double weft shots having every other double weft shotlying in a common lower plane and the intermediate double weft shotslying in a common upper plane, a chain warp extending over each lowerplane double weft shot and under each upper plane double weft shot, abinder warp extending over each upper plane double weft shot and undereach lower plane double weft shot, a straight stuffer warp extendingbetween the chain warp and the binder warp above the lower plane doubleweft shots and beneath the upper plane double weft shots, and a pileyarn warp end looped under each upper level double weft shot andextending as a loop pile over each lower level double weft shot andlying between the binder warp and the chain warp above the straightstuffer warp.

4. A two-shot modified Axminstcr carpet weave comprising a plurality ofclosely spaced double weft shots disposed in substantially the sameplane, a pile yarn warp end looped under each alternate double weft shotand extending as an uncut loop pile over each double weft shotintermediate the said alternate double weft shots, a double warp chainbinding together all said double weft shots, and a binder warp end ofstutter material extending over the intermediate double weft shots lyingbeneath the uncut loop piles and over the alternate double weft shots,said pile yarn end lying in front of the double warp chain and thebinder warp end and projecting below the chain binding underlying eachalternate double weft shot.

5. The combination of claim 4 in which the pile yarn warp end is of aplied yarn and each uncut loop pile is twisted into an open ringformation.

References Cited in the file of this patent UNITED STATES PATENTS DavisMay 25, 1920

